US20250215151A1 - Aromatic polyetherketone molded body and method of producing the same - Google Patents

Aromatic polyetherketone molded body and method of producing the same Download PDF

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Publication number
US20250215151A1
US20250215151A1 US18/852,855 US202318852855A US2025215151A1 US 20250215151 A1 US20250215151 A1 US 20250215151A1 US 202318852855 A US202318852855 A US 202318852855A US 2025215151 A1 US2025215151 A1 US 2025215151A1
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United States
Prior art keywords
molded body
peak
surface layer
aromatic polyetherketone
layer portion
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Pending
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US18/852,855
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English (en)
Inventor
Takeshi MAKABE
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Riken Corp
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Riken Corp
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Assigned to RIKEN, KABUSHIKI KAISHA reassignment RIKEN, KABUSHIKI KAISHA ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: MAKABE, TAKESHI
Publication of US20250215151A1 publication Critical patent/US20250215151A1/en
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    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J7/00—Chemical treatment or coating of shaped articles made of macromolecular substances
    • C08J7/12—Chemical modification
    • C08J7/123—Treatment by wave energy or particle radiation
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G65/00—Macromolecular compounds obtained by reactions forming an ether link in the main chain of the macromolecule
    • C08G65/34—Macromolecular compounds obtained by reactions forming an ether link in the main chain of the macromolecule from hydroxy compounds or their metallic derivatives
    • C08G65/38—Macromolecular compounds obtained by reactions forming an ether link in the main chain of the macromolecule from hydroxy compounds or their metallic derivatives derived from phenols
    • C08G65/40—Macromolecular compounds obtained by reactions forming an ether link in the main chain of the macromolecule from hydroxy compounds or their metallic derivatives derived from phenols from phenols (I) and other compounds (II), e.g. OH-Ar-OH + X-Ar-X, where X is halogen atom, i.e. leaving group
    • C08G65/4012—Other compound (II) containing a ketone group, e.g. X-Ar-C(=O)-Ar-X for polyetherketones
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
    • B29C35/08—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation
    • B29C35/0866—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using particle radiation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/16—Cooling
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K7/00—Use of ingredients characterised by shape
    • C08K7/02—Fibres or whiskers
    • C08K7/04—Fibres or whiskers inorganic
    • C08K7/06—Elements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
    • B29C35/08—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation
    • B29C35/0866—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using particle radiation
    • B29C2035/0877—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using particle radiation using electron radiation, e.g. beta-rays
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2071/00—Use of polyethers, e.g. PEEK, i.e. polyether-etherketone or PEK, i.e. polyetherketone or derivatives thereof, as moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2015/00—Gear wheels or similar articles with grooves or projections, e.g. control knobs
    • B29L2015/003—Gears
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G2650/00—Macromolecular compounds obtained by reactions forming an ether link in the main chain of the macromolecule
    • C08G2650/28—Macromolecular compounds obtained by reactions forming an ether link in the main chain of the macromolecule characterised by the polymer type
    • C08G2650/38—Macromolecular compounds obtained by reactions forming an ether link in the main chain of the macromolecule characterised by the polymer type containing oxygen in addition to the ether group
    • C08G2650/40—Macromolecular compounds obtained by reactions forming an ether link in the main chain of the macromolecule characterised by the polymer type containing oxygen in addition to the ether group containing ketone groups, e.g. polyarylethylketones, PEEK or PEK
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2371/00—Characterised by the use of polyethers obtained by reactions forming an ether link in the main chain; Derivatives of such polymers

Definitions

  • the present invention relates to an aromatic polyetherketone molded body that can be used for various parts and a method of producing the same.
  • An infrared absorption spectrum is obtained by measurement using an infrared spectrophotometer for both the body portion and the surface layer portion, the infrared absorption spectrum including a peak A and a peak B, the peak A appearing in a wavenumber range of 1295 to 1340 cm ⁇ 1 , the peak B appearing in a wavenumber range of 1265 to 1295 cm ⁇ 1 .
  • the aromatic polyetherketone molded body may be configured as a gear member.
  • a method of producing an aromatic polyetherketone molded body includes the steps of: preparing a molded body from which an infrared absorption spectrum is obtained by measurement using an infrared spectrophotometer, the infrared absorption spectrum including a peak A and a peak B, the peak A appearing in a wavenumber range of 1295 to 1340 cm ⁇ 1 , the peak B appearing in a wavenumber range of 1265 to 1295 cm ⁇ 1 ; and applying an electron beam to a surface of the molded body.
  • FIG. 1 is a flowchart showing a method of producing a resin molded body according to an embodiment of the present invention.
  • FIG. 2 is a diagram showing an example of an infrared absorption spectrum of the resin molded body.
  • FIG. 3 is a graph showing a change a ratio A′/B′ depending on an irradiation dose of an electron beam.
  • the resin molded body according to the present invention may be formed of an aromatic polyetherketone including an additive.
  • the additive include a fibrous filler, a non-fibrous filler, and a solid lubricant.
  • the infrared absorption spectrum of the aromatic polyetherketone includes a peak A appearing in a wavenumber range of 1295 to 1340 cm ⁇ 1 and a peak B appearing in a wavenumber range of 1265 to 1295 cm ⁇ 1 .
  • the degree of crystallization of the aromatic polyetherketone is evaluated by a ratio A′/B′ of strength A′ obtained as the height of the peak A to strength B′ as the height of the peak B. That is, it can be seen that in the aromatic polyetherketone, the larger the ratio A′/B′, the higher the degree of crystallization, and the smaller the ratio A′/B′, the lower the degree of crystallization.
  • Step S 02 the raw material resin prepared in Step S 01 is molded.
  • a known molding method such as injection molding and extrusion molding can be used.
  • the tact time can be shortened by rapidly cooling the mold before the stage taking out the molded body of the raw material resin after molding.
  • the molded body of the raw material resin taken out from the mold may be subjected to processing for modifying the shape, such as cutting and grinding.
  • Step S 03 an electron beam is applied to the entire surface of the molded body of the raw material resin obtained in Step S 02 .
  • the electron beam that has entered the surface promotes crystallization of the amorphous portion in the aromatic polyetherketone forming the vicinity of the surface and increases the degree of crystallization in the vicinity of the surface.
  • Step S 03 application of an electron beam obtains a resin molded body that includes a surface layer portion whose degree of crystallization has been increased and a body portion that is located on the inner side of the surface layer portion and is not affected by the application of an electron beam.
  • the degree of crystallization immediately after Step S 02 is maintained in the body portion covered with the surface layer portion.
  • FIG. 2 shows an example of an infrared absorption spectrum of the surface layer portion and the body portion in the resin molded body according to this embodiment.
  • the infrared absorption spectrum of the surface layer portion is obtained by, for example, measurement of absorbance of the surface of the resin molded body.
  • the infrared absorption spectrum of the body portion is obtained by, for example, measurement of absorbance of a cross section obtained by cutting the resin molded body to expose the body portion.
  • FIG. 2 shows the absorption spectrum of the surface layer portion by a broken line and the absorption spectrum of the body portion by a solid line. While the strengths B′ of the peak B are equivalent to each other between the surface layer portion and the body portion, the strength A′ of the peak A is higher in the surface layer portion than in the body portion. That is, in the resin molded body according to this embodiment, the ratio A′/B′ of the strengths A′ and B′ is larger in the surface layer portion than in the body portion.
  • the resin molded body according to this embodiment by increasing the degree of crystallization of the surface layer portion, it is possible to increase the mechanical strength in the vicinity of the surface where large stress is likely to be applied from the outside. As a result, in the resin molded body according to this embodiment, it is possible to suppress the progress of wear and the occurrence of chipping in the vicinity of the surface formed by the surface layer portion.
  • the resin molded body according to this embodiment it is possible to increase only the mechanical strength of the surface layer portion without increasing the mechanical strength of the body portion by applying an electron beam. As a result, in the resin molded body according to this embodiment, the effect of suppressing the occurrence of damage by the synergistic effect between the surface layer portion and the body portion can be achieved.
  • the thickness of the surface layer portion in the resin molded body according to this embodiment can be appropriately determined in accordance with the application or the like. For example, from the viewpoint of more reliably achieving the above effect of the surface layer portion, it is favorable to set the thickness of the surface layer portion to 50 ⁇ m or more. Meanwhile, from the viewpoint of more effectively achieving the shock absorbing properties of the body portion, it is favorable to limit the thickness of the surface layer portion to 700 ⁇ m or less.
  • the thickness of the surface layer portion in the resin molded body can be controlled in various ways by changing the conditions for applying an electron beam.
  • large-scale equipment is necessary to increase the thickness of the surface layer portion, it is favorable to limit the thickness of the surface layer portion to 700 ⁇ m or less from the viewpoint of keeping the production cost low without using large-scale equipment.
  • FIG. 3 is a graph plotting the ratio A′/B′ of the surface layer portion when changing the irradiation dose of an electron beam in Step S 03 . Note that in all plots in FIG. 3 , the other conditions for applying an electron beam and the configuration of the molded body of the raw material resin were common. Further, the plot of the zero irradiation dose in FIG. 4 indicates the condition for applying no electron beam.
  • Step S 03 it is favorable to apply an electron beam while heating the molded body of the raw material resin. This makes it easier for the resin molded body to achieve the effect of improving the mechanical strength of the surface layer portion, e.g., it is possible to further improve the fracture properties. It is favorable to set the temperature of the molded body of the raw material resin during application of an electron beam to, for example, 200° C. or more.
  • the resin molded body according to this embodiment is particularly suitable for application to a part where stress is likely to concentrate on the surface.
  • a part examples include a sliding member such as a gear member, a seal ring, a thrust washer, and a bearing.
  • a sliding member such as a gear member, a seal ring, a thrust washer, and a bearing.
  • the resin molded body configured as a sliding member it is possible to suppress the occurrence of damage and reduce the friction loss.
  • FIG. 4 shows a gear member as an application example of a sliding member of the resin molded body according to this embodiment.
  • stress tends to concentrate at the tooth roots of a plurality of teeth T arranged along the outer periphery, but the occurrence of chipping of the teeth T can be effectively suppressed by configuring the resin molded body according to this embodiment.
  • Examples and Comparative Examples of the above embodiment will be described.
  • samples of resin molded bodies were prepared, and each of the samples was evaluated.
  • An electron beam was applied to the molded body of the raw material resin in all Examples 1 to 8, and no electron beam was applied to the molded body of the raw material resin in both Comparative Examples 1 and 2.
  • Example 1 PEEK was used as a raw material resin. Specifically, “VESTAKEEP (registered trademark) 4000G” manufactured by Daicel-Evonik Ltd. was used. Further, in Example 4, PEK was used as a raw material resin. Specifically, “VICTREX (registered trademark) HT” manufactured by Victrex plc. was used. Further, in Example 5, 20 weight % of carbon fiber and 10 weight % of PTFE were contained in the raw material resin as additives.
  • an electron beam was applied at room temperature. Further, in Examples 1 to 3, an electron beam was applied at irradiation doses different from each other. Specifically, the irradiation dose was set to 50 kGy in Example 1, the irradiation dose was set to 100 kGy in Example 2, and the irradiation dose was set to 200 kGy in Example 3. Further, the irradiation dose was set to 100 kGy in Example 4, and the irradiation dose was set to 200 kGy in Example 5.
  • All the samples according to Examples 1 to 5 had a common configuration except for the configuration described above. Further, as the sample according to Comparative Example 1, the molded body of the raw material resin before applying an electron beam in the samples according to Examples 1 to 3 was used. The absorbances of the surface layer portion and the body portion of the samples according to Examples 1 to 5 and Comparative Example 1 were measured using an infrared spectrophotometer. The absorbance was measured by an ATR method with a Ge lens using a Fourier transformation infrared spectrophotometer “FT/IR-4600” manufactured by JASCO Corporation.
  • FT/IR-4600 Fourier transformation infrared spectrophotometer
  • the ratio A′/B′ was calculated from each infrared absorption spectrum obtained by measurement of absorbance.
  • Table 1 shows the ratio A′/B′ of the surface layer portion and the body portion in Examples 1 to 5 and Comparative Example 1. While the ratios A′/B′ were equal to each other between the surface layer portion and the body portion in Comparative Example 1, the ratio A′/B′ was higher than in the surface layer portion than in the body portion in all Examples 1 to 5.
  • a conical indenter formed of sapphire, an included angle of 90°, a tip curvature radius of 0.05 mm
  • the load was set to 150 gf
  • the sliding speed was set to 300 mm/min
  • the moving distance was set to 10 mm
  • other conditions were also common.
  • “OK” and “NG” were determined by the presence or absence of the wear of 100 ⁇ m or more.
  • a tensile test was conducted on each of the samples according to Examples 1 to 3 and Comparative Example 1.
  • “AGX” manufactured by Shimadzu Corporation was used.
  • each sample was formed into an A12 type dumbbell shape conforming to JIS K7139 (2009).
  • the tensile speed was set to 10 mm/min and the other conditions were also common.
  • Table 1 shows the breaking strength as the change rate (%) in Examples 1 to 3 with reference to Comparative Example 1. As shown in Table 1, it can be seen that all samples according to Examples 1 to 3 had higher breaking strength than the sample according to Comparative Example 1 and high breaking strength is obtained by the effect of the surface layer portion.
  • a tear test was conducted on each of the samples according to Examples 1 to 3 and Comparative Example 1.
  • “AGX” manufactured by Shimadzu Corporation was used.
  • each sample was formed into a strip shape (with a 1 mm notch) of 10 mm ⁇ 80 mm ⁇ 0.1 mm.
  • the tensile speed was set to 10 mm/min and the other conditions were also common.
  • Table 1 shows the dynamic friction coefficient as the change rate (%) in Examples 1 to 3 with reference to Comparative Example 1. As shown in Table 1, it can be seen that in each of the samples according to Examples 1 to 3, the dynamic friction coefficient was lower than that of the sample according to Comparative Example and high sliding properties as a sliding member is achieved by the effect of the surface layer portion.
  • Table 1 shows the results of the gear fatigue test in Examples 1 to 3 and Comparative Example 1. As shown in Table 1, while no tooth chipping occurred in all samples according to Examples 1 to 3, tooth chipping occurred in the sample according to Comparative Example 1. As a result, it can be seen that in Examples 1 to 3, high fatigue properties as a gear member can be achieved.
  • Example 6 the sample temperature during application of an electron beam was changed from that in Example 2. Specifically, the sample temperature was set to 200° C. in Example 6, the sample temperature was set to 250° C. in Example 7, and the sample temperature was set to 300° C. in Example 8. Further, in all Examples 6 to 8, the irradiation dose of an electron beam was set to 100 kGy, similarly to Example 2.
  • Example 6 the conditions for applying an electron beam in Examples 6 to 8 are different from those in Example 2 in which the sample temperature is room temperature in that the sample is heated.
  • Example 6 the conditions for applying an electron beam in Examples 6 to 8 are different from those in Example 2 in which the sample temperature is room temperature in that the sample is heated.
  • a tensile test was conducted on each of the samples according to Examples 6 to 8. The conditions of the tensile test were the same as those in the above Examples 1 to 3 and Comparative Example 1.
  • Table 2 shows the breaking strength as the change rate (%) in Examples 2 and 6 to 8 with reference to Comparative Example 1. As shown in Table 2, it can be seen that in the samples according to Examples 6 to 8 in which an electron beam was applied while heating the sample, higher breaking strength than that of the sample according to Example 2 is achieved.
  • the sample according to Comparative Example 1 was subjected to heat treatment (annealing treatment) at 300° C. to prepare a sample according to Comparative Example 2. That is, the sample according to Comparative Example 2 is the same as the sample according to Example 8 in that the molded body of the raw material resin is heated to 300° C. but is different from the sample according to Example 8 in that no electron beam is applied.
  • heat treatment annealing treatment
  • Example 8 A tensile test similar to that in Example 8 was conducted on the sample according to Comparative Example 2.
  • Table 3 shows the breaking strength as the change rate (%) in Example 8 with reference to Comparative Example 2. As shown in Table 3, it can be seen that in the sample according to Example 8 in which an electron beam was applied while heating the sample, higher breaking strength than that of the sample according to Comparative Example 2 in which the sample was simply heated is achieved.

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  • Chemical Kinetics & Catalysis (AREA)
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  • Polymers & Plastics (AREA)
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  • Injection Moulding Of Plastics Or The Like (AREA)
  • Investigating Or Analysing Materials By Optical Means (AREA)
  • Manufacture Of Macromolecular Shaped Articles (AREA)
US18/852,855 2022-04-27 2023-03-27 Aromatic polyetherketone molded body and method of producing the same Pending US20250215151A1 (en)

Applications Claiming Priority (3)

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JP2022-073067 2022-04-27
JP2022073067A JP7721480B2 (ja) 2022-04-27 2022-04-27 芳香族ポリエーテルケトン成形体、及びその製造方法
PCT/JP2023/012216 WO2023210235A1 (ja) 2022-04-27 2023-03-27 芳香族ポリエーテルケトン成形体、及びその製造方法

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